Spray iron

ABSTRACT

The invention is directed to an electric flatiron equipped with a sprayer and consists of improvements in the spray mechanism whereby cavities, which normally trap undesired air or water on the pump suction stroke are filled, so that, structurally, no undesired fluids can be trapped. Additionally, the outer surface of the spray orifice is dished to provide a natural path away from the orifice so water does not form over the orifice to be drawn into the sprayer on the suction stroke. The entire sprayer mechanism may be a non-metallic molded plastic in several modifications.

limited States Patent Walker et al. [451 May 23, 1972 [54] SPRAY IIRQN 3,373,516 3/1968 Knapp et al ..3s 77.s [72] Inventors: Wendell C. Walker, Alta Loma; William E. Davidson, Ontario, both of Calif.

Primary Examiner-P. D. Lawson Attorney-Lawrence R. Kempton, Leonard J. Platt, John F. Cullen, Frank L. Neuhauser, Oscar B. Waddell and Joseph B. Forman ABS I'RACT The invention is directed to an electric flatiron equipped with a sprayer and consists of improvements in the spray mechanism whereby cavities, which normally trap undesired air or water on the pump suction stroke are filled, so that, structurally, no undesired fluids can be trapped. Additionally, the outer surface of the spray orifice is dished to provide a natural path away from the orifice so water does not form over the orifice to be drawn into the sprayer on the suction stroke. The entire sprayer mechanism may be a non-metallic molded plastic in several modifications.

6 Claims, 4 Drawing Figures SPRAY IRON l. Field of the Invention The invention is directed to an improved fluid sprayer for an electric flatiron generally, although not so limited, of the mechanical pump type whereby a pump stroke from a button on the iron handle directs a water spray onto the ironing surface on each actuation of the pump. Each pump stroke should immediately direct a smooth homogenous spray free of any globs or droplets.

2. Description of the Prior Art It is common in steam irons to provide means to spray water onto the fabric being ironed since many fabrics cannot be satisfactorily ironed unless some moisture is present in the fabric during application of heat. Thus, steam irons have been developed which, in addition to dispensing moist steam onto the fabric during the ironing process, also provide a spray mechanism to spray water onto the fabric. A common system uses steam pressure generated within the iron to provide pressure to force the water outwardly through the spray mechanism and is known as a power spray. Other manual systems use piston, bellows, or diaphragm-type pumps associated with the water tank to provide sprayer operation. Such pumps being manually operated, are readily adapted for spraying during dry ironing. These pumps generally lift water from the water tank and pass it through a known spray mechanism as a fine spray. One of the difficulties of such sprayers is the spray mechanism generally has cavities which trap undesired air and water caused by the manual compression stroke followed by the suction stroke where the remaining water around the orifice is sucked back and mixed with air into the sprayer cavities. On the next compression or pump stroke it is expelled as blobs or small droplets since it is trapped in the passage cavities that must be cleared before the main spray emerges. When the pumping stroke is terminated, the last drop forms on or around the orifice and is drawn back into the sprayer on the suction stroke or evaporates over the orifice and eventually clogging it with tap water residues. The result is that the spraying characteristic is not completely satisfactory because of the initial discharge of the trapped fluid in a form other than the fine mist desired and the eventual clogging of the orifice.

SUMMARY OF THE INVENTION Briefly described, the invention is directed to an electric flatiron with a fluid sprayer directed forwardly on actuation of means on the handle usually in the form of a button. The usual sprayer includes a tubular body connected to the iron and to a fluid supply and employs a cap means telescopically engaging around the body to bear against one end surface of the body and having a central spray orifice. The body holds a springbiased spreader member with an end face having radial grooves whereby fluid passes between the spreader and the body, then through the grooves, and then out the orifice in the form of a fine spray. In this conventional arrangement the invention improves on the sprayer mechanism by providing means between the cap and the body to fill the cavity or volume radially outward of the grooves so that no space is available for the storage of fluid. Additionally, the spray includes a dished concentric recess around the orifice of the cap on its outer surface so that fluid is prevented from collecting where it can be drawn back into the sprayer on the suction stroke of the pump or can evaporate over the orifice. The cap can be a single or two-piece construction in several modifications and may conveniently be made of a non-metallic molded material such as a plastic for easy formation directly thereon of fill means. In the plastic form, the parts may be deformed to create a seal when the parts are fastened together. Also, a molded plastic forms smooth rounded edges with no rough surfaces in the fine passages to interfere with the fluid flow as occurs in some metal parts. Thus, the main object of the invention is to provide an improved sprayer mechanism that ensures a continuous, repetitive, finely divided spray with no large droplets and structurally prevents the condition under which droplets can form. The use of molded material, in addition to achieving the desired characteristics, also results in a lower cost spray mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial sectional elevation view of the forward portion of a steam/spray iron illustrating conventional structure;

FIG. 2 is a partial sectional view of the sprayer mechanism of the invention showing a different modification on each side of the center line;

FIG. 3 is a view similar to FIG. 2 showing another form of the invention with a single-piece cap and;

FIG. 4 is a view similar to FIG. 2 showing the invention employing a two-piece cap.

DESCRIPTION OF THE PREFERRED EMBODIMENT While the invention is applicable to a spray iron for any fluid, whether powered or manual, for convenience it will be described in connection with a manual water spray steam iron.

The present invention is an improvement on the conventional structure as shown in US. Pat. No. 3,183,61 l Swenson of common ownership and FIG. 1 is substantially FIG. 1 of that patent. Referring to FIG. 1, there is shown the forward portion of a steam and spray iron having a handle 10, a cover 12, and a soleplate 14. Mounted in the cover 12 is water tank 16 with a drip valve 18 in its bottom wall whereby water in the tank is dispensed through valve 18 onto the soleplate to flash into steam when the soleplate is heated by heater 20. A coverplate 22 is fixed to the top of the soleplate to provide a path for the passage of steam from steam generator 24 to a plurality of steam outlets 26 where it passes into the fabric being ironed. In order to convey water to a fluid sprayer 28, a diaphragm pump 30 is mounted in the hollow forward handle portion of the iron. Water tube 32 connects the water tank with the sprayer mechanism through a uni-directional valve 34 which passes the water into the diaphragm pump 30.

The fluid sprayer 28 is connected to pump 30 and includes a tubular sprayer body 36, a cap means 38, having a flat outer end surface with an orifice 40 and telescopically threaded on body 36. The cap is threaded on the body to bear flat against one end surface of the body as shown. The spray is created by a spring-biased spreader member 42 which has a flat end face abutting the inner surface of the cap and with a plurality of radial grooves 44. A ball check valve provides one-way flow of fluid through the sprayer 28. Spreader member 42 insures an even flow of water to orifice 40 and also aids in the spraying by imparting a whirling action to the water through the radial grooves 44. Pump 30 is actuated through linkage by means, such as button 48 on the iron handle, so that the diaphragm is compressed on the downward stroke and spray is expelled from sprayer 28. Conversely with each actuation of the button, on the upward or suction stroke any water or fluid remaining in the passages is limited by ball check valve 46 and valve 34 from backward flow. Thus, on the compression or pumping stroke, water passes between spreader 42 and spreader body 36, through radial grooves 44, and then out through orifice 40. The structure thus far described is conventional and fully shown and described in the abovementioned Swenson patent.

It has been found in practice that fluid sprayers of the type described have a tendency to trap water and air that are sucked back into the cavity or space 50 that is formed between the end of tubular sprayer body 36 and cap 38. This occurs because, when the pump stroke is completed, a small drop of water tends to adhere to the flat outer face of the cap over the orifice. Then, on the next suction stroke this drop is drawn back through the orifice and trapped in cavity 50 where it is subsequently expelled as a glob whereby the iron spits on the next pumping stroke before the regular spray emerges as the desired fine mist. When spraying is completed, any remaining water in the mechanism may leak out the orifice and adhere to the outer surface of the cap over the orifice until, in time, it evaporates. If there are dissolved residues these tend to clog the orifice.

In order to overcome the above disadvantages of spitting because of the tendency of water to adhere to the orifice and be drawn back into the cavities, or to evaporate over the orifice and tend to close it with any residues, the present invention improves on the sprayer mechanism in two ways. First, means are provided between the cap and the sprayer body to fill any space or cavity that lies radially outward of the spreader grooves to prevent water from collecting upstream of the grooves to be trapped and expelled on the next pump stroke. In conjunction with this, a dished concentric recess is provided around the orifice on the outer cap surface whereby water left on the outer surface inherently flows away from the orifice leaving it clear at all times. These advantages are obtained by several modifications.

Referring to FIG. 2, there is shown a non-threaded sprayer cap structure that may be in a single piece as shown on one side of the center line or as a two-piece component as shown on the other side of the center line. Referring to the singlepiece structure, sprayer body 36 may be threaded lengthwise at 52 on its outer surface and may have an unthreaded extension 54. Integral or one-piece cap means 56 may be formed with threads to match 52 and a sliding close telescopic fit on extension 54 whereby the cap may be screwed down to threadably engage the body and provide a snug fit on the end face 58 of sprayer body 36. Thus, the extension 54 and its flatface contact with the inner surface of the cap serves as a fill means between the cap and the body to fill in the space that is radially outward of grooves 44 in the flat end of spreader member 42. In other words, the usual cavity or volume 50 shown in FIG. I is completely eliminated. Any suitable sealing means may be used along the surface of face 58 if necessary such as a bead of silicone. If the cap 56 is made of a nonmetallic molded plastic the plasticity of the material itself forms a tight seal bearing on the hard metallic end face 58 of the body member.

While the water collection is avoided by eliminating any cavities, it is also desirable to eliminate the condition whereby the water is present to be drawn back into the pump and, to this end, the outer surface of the cap is provided with an integral dished concentric recess 60 as shown around the orifice and which is designed to flow water away from orifice 40 so that any water left on the cap face tends to run down to the lower portion of the cap surface and drip off harmlessly. Additionally, if a non-metallic plastic is used it enhances this tendency by providing a wetter surface thus easing the flow of water away from the orifice. The orifice also does not require cleaning since the water no longer dries over it to leave any residue. The other portion of FIG. 2 shows substantially the same general cap structure in a two-piece form where one piece 62 has the orifice 40 therein and the other piece 64 acts as a locknut and engages the iron at 66 to lock the sprayer assembly in position on the iron. Any suitable interlocking connection such as overlapping flanges 68 may be used to hold or lock the two pieces together. The relatively tight fit between piece 62 and body 36 eliminates the need for threads and piece 62 is again pulled tightly against end face 58 to eliminate any cavity that can trap water. Suitable sealing material may be used between the parts as required so long as it is not used in a manner that creates any cavities where water can be trapped as shown at 50in FIG. 1.

Referring next to FIG. 3, a modification of the single-piece cap is again shown and is similar to that of the single form of FIG. 2. In this modification, single cap 70 may be made of a non-metallic molded plastic such as a polysulfone or what is generally known as an engineering grade thermoplastic in having good properties at high temperatures such as ability to withstand heat distortion above 220 F; it must be non-inflammable; and it cannot have poor creep characteristics. A

molded cap permits the use of more intricate construction such as a formed integral shoulder 72 along the periphery of the inner cap surface radially outward of grooves 44 to completely fill and compress against the end face of spreader member 42. In this modification, the cap also includes recess 60 and may have internal threads for engaging on spreader body 36 at 76 as shown. Any suitable gasket 78 may be used to seal between the cap and body. Again the substantial filling of any cavity in conjunction with the outer recess provides for a uniform mist over the full pump stroke on each actuation and there is no trapping of fluid within the sprayer mechanism or over the sprayer orifice when the spray is terminated. This structure does have one slight disadvantage in that as a singlepiece cap the size of the cavity is a function of the tightening of the cap which is done by a torque wrench but it is still not always possible to tell when the cap is seated against end face 58 so that all cavities are completely filled. Thus, it is still possible to leave a slight cavity or unfilled opening between the cap and body which can change the spray characteristics.

To overcome this objection, a second two-piece cap component as shown in FIG. 4 may be employed. The parts are substantially the same as those shown in the two-piece version of FIG. 2 and the operation is the same and each piece is threadedly locked to the body. In this figure, the one piece 80 having the orifice may be locked to the sprayer body 36 by threads 82. It can be seen that the one piece 80 is then adjustable independently and the spray may be tested and then properly set as a separate operation on the assembly line. If a clear plastic is used the elimination of any cavity by tightening down piece 80 is visible when the spray is actuated i.e. it is possible to see whether any cavity is trapping water. The spray mechanism is then secured in the iron 66 by the second piece 84 of larger diameter to slide over smaller diameter piece 80 and engage the iron to hold the sprayer and act as a locknut when threaded up against the iron all without affecting the spray. This second piece may thus be put on on the assembly after the proper spray has been adjusted independently by piece 80. Again, if required, a line of silicone 86 may be used as a seal or, if non-metallic plastic, the plastic itself is sufficiently deformable to act as a seal between the plastic and metal.

The invention actually accomplishes two main functions and several side benefits to improve on conventional structure. First, by providing a fill means between the cap and body, any cavities which trap water are completely removed to provide a continuous mist over the full range of each sprayer stroke. Second, the dished recess on the outer surface of the cap around the orifice directs water away from the orifice so that it remains clean and does not act as a reservoir for water to be pulled back into the spray mechanism on the suction stroke of the pump. As an added benefit, the use of nonmetallic parts permits intricate and accurate molding wherein any cavity may be easily filled by molding the filler as part of the cap itself while allowing easy sealing since the plastic can be squeezed against the metallic surface. Finally, a molded plastic permits the elimination of any sharp corners, rough edges, flashing, or minute particles all of which can occur in a new metallic sprayer and must be purged to avoid difficulty in spraying or uneven spraying. The improved sprayer mechanism built in accordance with the invention has been found to be cheaper and better operating in accordance with the objectives noted.

While there have been described preferred forms of the invention, obvious equivalent variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practised otherwise than as specifically described and the claims are intended to cover such equivalent variations.

We claim:

1. In an electric flatiron having a fluid sprayer directed forwardly on actuation of means on the handle and the sprayer including, a tubular body connected to the iron and to a fluid supply, cap means having a central orifice and telescopically engaging around said body to bear against one end surface of the body, and a spring-biased flat-ended spreader member in said body with an end face having radial grooves whereby fluid passes between the spreader and body, through the grooves, and then out the orifice, the improvement in the sprayer mechanism comprising,

means between said cap and body to fill the space therein radially outward of said grooves and,

a dished concentric recess around said orifice on and integral with the outer cap surface,

whereby fluid is prevented from collecting upstream of said grooves and over said orifice when sprayer action is terminated.

2. Apparatus as described in Claim 1 wherein said actuation means is a button on said iron handle and said sprayer is a manual sprayer creating a suction and a compression stroke on each actuation of said button.

3. Apparatus as described in claim 2 wherein said tubular body is threaded lengthwise on its outer surface and said cap means has an inner surface abutting said flat-ended member and is threadably engaged around said body,

said cap being a non-metallic molded cap and,

said fill means including a formed integral shoulder along the periphery of the inner cap surface thereof and radially outward of said grooves to substantially fill the space between said cap and the end of said body threads and the non-metallic recess spreads said fluid over the outside of said cap away from said orifice.

4. Apparatus as described in claim 2 wherein said cap is a two-piece component,

one piece having the orifice therein and the other piece engaging said iron to hold said sprayer and,

means locking said pieces to said body,

whereby said one piece is independently adjustable of said other piece.

5. Apparatus as described in claim 4 wherein said means locking said pieces to said body includes threads on each plece.

6. Apparatus as described in claim 4 wherein said two-piece cap is a non-metallic molded cap,

said one piece being of smaller diameter and threaded on said body and,

said other piece being of larger diameter to slide over said one piece and threaded on said body to lock said sprayer to said iron,

whereby said one piece containing the orifice is independently adjustable on said body. 

1. In an electric flatiron having a fluid sprayer directed forwardly on actuation of means on the handle and the sprayer including, a tubular body connected to the iron and to a fluid supply, cap means having a central orifice and telescopically engaging around said body to bear against one end surface of the body, and a spring-biased flat-ended spreader member in said body with an end face having radial grooves whereby fluid passes between the spreader and body, through the grooves, and then out the orifice, the improvement in the sprayer mechanism comprising, means between said cap and body to fill the space therein radially outward of said grooves and, a dished concentric recess around said orifice on and integral with the outer cap surface, whereby fluid is prevented from collecting upstream of said grooves and over said orifice when sprayer action is terminated.
 2. Apparatus as described in Claim 1 wherein said actuation means is a button on said iron handle and said sprayer is a manual sprayer creating a suction and a compression stroke on each actuation of said button.
 3. Apparatus as described in claim 2 wherein said tubular body is threaded lengthwise on its outer surface and said cap means has an inner surface abutting said flat-ended member and is threadably engaged around said body, said cap being a non-metallic molded cap and, said fill means including a formed integral shoulder along the periphery of the inner cap surface thereof and radially outward of said grooves to substantially fill the space between said cap and the end of said body threads and the non-metallic recess spreads said fluid over the outside of said cap away from said orifice.
 4. Apparatus as described in claim 2 wherein said cap is a two-piece component, one piece having the orifice therein and the other piece engaging said iron to hold said sprayer and, means locking said pieces to said body, whereby said one piece is independently adjustable of said other piece.
 5. Apparatus as described in claim 4 wherein said means locking said pieces to said body includes threads on each piece.
 6. Apparatus as described in claim 4 wherein said two-piece cap is a non-metallic molded cap, said one piece being of smaller diameter and threaded on said body and, said otHer piece being of larger diameter to slide over said one piece and threaded on said body to lock said sprayer to said iron, whereby said one piece containing the orifice is independently adjustable on said body. 